Method for producing electrically conductive members

ABSTRACT

A method for producing a pair of electrically conductive members assembled into an electrical component assembly provided with a coil. The method includes: forming connection terminal sections provided in the pair of electrically conductive members by arranging them alternately opposite to each other and then performing press punching; and after the press punching, bending the connection terminal sections in the pair of electrically conductive members toward a side departing from the coil into a protruding form.

CROSS REFERENCE TO RELATED APPLICATION(S)

The present disclosure relates to the subject matters contained inJapanese Patent Application No. 2010-251195 filed on Nov. 9, 2010,Japanese Patent Application No. 2010-104126 filed on Apr. 28, 2010,Japanese Patent Application No. 2010-251193 filed on Nov. 9, 2010, andJapanese Patent Application No. 2010-251194 filed on Nov. 9, 2010, whichare incorporated herein by reference in its entirety.

BACKGROUND 1. Field

The present invention relates to a connection structure for electricalcomponent assembly, a hydraulic pressure control apparatus, and a methodfor producing electrically conductive member.

2. Description of the Related Art

In a vehicle brake hydraulic pressure control apparatus serving as anexample of a hydraulic pressure control apparatus, a connectionstructure of electrically connecting an electrical component assembly toa housing mounted on a base is known, for example, as disclosed inJP-A-2007-153305 and JP-A-2003-175812.

JP-A-2007-153305 and JP-A-2003-175812 disclose connection structures inwhich connection terminal sections of electrically conductive membersprovided in an electrical component assembly provided with a coil risealong the axis direction of the coil, and then are fixed by welding tohousing-side connection terminals provided on the housing side.

Here, the electrically conductive members are manufactured by presspunching from a metal plate or the like.

Nevertheless, in the configurations disclosed in JP-A-2007-153305 andJP-A-2003-175812, since the connection terminal sections of theelectrically conductive members provided in the electrical componentassembly rise along the axis direction of the coil, a space need beensured in the direction of rise. Thus, size increase may be caused in avehicle brake hydraulic pressure control apparatus serving as anassembled apparatus on which a apparatus having this configuration ismounted.

Further, since the electrically conductive members rise along the axisdirection of the coil, at the time of manufacturing of the electricallyconductive members from a metal plate or the like by press punching, thepunching need be performed in a larger size by the length of the rise.This may cause a larger loss in the material so as to degrade aso-called production yield, and thereby may cause difficulty inimprovement of the manufacturing efficiency.

In a vehicle brake hydraulic pressure control apparatus serving as anexample of a hydraulic pressure control apparatus, a connectionstructure of electrically connecting an electrical component assembly toa housing mounted on a base is known, for example, as disclosed inJP-A-2003-175812.

JP-A-2003-175812 discloses a connection structure in which connectionterminal sections of electrically conductive members provided in anelectrical component assembly provided with a coil are electricallyconnected by welding to housing-side connection terminals of a bus barconnected by wire bonding.

The welding between the connection terminal sections of the electricallyconductive members and the housing-side connection terminals has beenperformed, after the electrical component assembly is assembled in thehousing, by inserting the tip part of the electrical connection jig fromthe opening side and then pinching them with the tip part of theelectrical connection jig.

Nevertheless, in the technique disclosed in JP-A-2003-175812, a certainspace used for insertion of the tip part of the electrical connectionjig need be ensured in the housing. This may cause size increase in thehousing or in a hydraulic pressure control apparatus to which thehousing is assembled.

A configuration of a hydraulic pressure control apparatus used in avehicle is disclosed, for example, in which a housing has anintermediate wall that separates an accommodation chamber foraccommodating a circuit board from an accommodation chamber foraccommodating an electrical component assembly such as a coil device(see JP-A-2003-175812, for instance).

In this hydraulic pressure control apparatus, a hole corresponding tothe electrical component assembly is formed in the intermediate wall.Then, the electrical component assembly is mounted through this hole.

In the hydraulic pressure control apparatus described inJP-A-2003-175812, although a hole is formed in the intermediate wall,the entire circumference of the electrical component assembly isenclosed by the intermediate wall. Thus, the intermediate wall occupiesa large space, and hence a large amount of resin material need be usedfor molding of the intermediate wall. This may cause cost increase andweight increase in the housing.

SUMMARY

A first object of the present invention is to provide a connectionstructure for electrical component assembly, a hydraulic pressurecontrol apparatus, and a method for producing electrically conductivemember in which size reduction of an assembled apparatus is achieved andthe production yield is improved so that the manufacturing efficiency isimproved.

With the first object in mind, there is provided a connection structurefor electrical component assembly including an electrical componentassembly provided with a coil energized through a pair of electricallyconductive members; and a housing that covers the electrical componentassembly and that is provided with housing-side connection terminals,wherein each of the electrically conductive members has a connectionterminal section connectable to the housing-side connection terminal,wherein the connection terminal section is bent toward a side departingfrom the coil so as to protrude toward a side of the electricalcomponent assembly, and one of the connection terminal sections isarranged at a position deviated in an axis direction of the coilrelative to the other of the connection terminal sections.

According to this connection structure for electrical componentassembly, the connection terminal sections of the pair of electricallyconductive members are bent toward a side departing from the coil so asto protrude toward the electrical component assembly, and one connectionterminal section is arranged at a position deviated in an axis directionof the coil relative to the other connection terminal section. Thus, incomparison with a case that the connection terminal sections of theelectrically conductive members rise along the axis direction of thecoil like in the related art, the size is reduced in the axis directionof the electrical component assembly which is equal to the axisdirection of the coil. Thus, size reduction is achieved in a housinginto which an electrical component assembly is assembled and in anassembled apparatus to which this housing is assembled like a vehiclebrake hydraulic pressure control apparatus.

Further, at the time of forming the electrically conductive members froma metal plate or the like by press punching, the electrically conductivemembers are formed by press punching by using a layout that theconnection terminal sections of the electrically conductive members arelocated alternately opposite to each other on the metal plate. Thisminimizes unnecessary parts after the press punching. Thus, incomparison with the related art, a loss in the material is reduced andthe production yield is improved. This realizes cost reduction andimproves the manufacturing efficiency.

Further, in the connection structure for electrical component assembly,the housing may have an intermediate wall extending in a directionparallel to a protruding direction of the connection terminal sectionsand a part of the housing-side connection terminals may be embedded inthis intermediate wall, and that the electrically conductive members maybe electrically connected to the housing-side connection terminals in acrossed state.

According to this connection structure for electrical componentassembly, the connection terminal sections of the electricallyconductive members are electrically connected in a crossing state to thehousing-side connection terminals of the intermediate wall extending ina direction parallel to the protruding direction of the connectionterminal sections. Thus, the housing-side connection terminals arearranged on the housing-side in a space-saving manner. Further, theelectrically conductive members protrude toward the housing-side iscontrolled. This permits size reduction of an assembled apparatus suchas a vehicle brake hydraulic pressure control apparatus on which theelectrical component assembly is mounted.

Further, in the housing, components such as a control board are allowedto be arranged close to the electrical component assembly. Thisincreases flexibility in the design.

Further, in the connection structure for electrical component assembly,the electrical component assembly may include a bobbin around which thecoil is wound, and wherein the bobbin may be provided with a terminalsupporting section for supporting the bent portions of the connectionterminal sections with the bent portions included in the terminalsupporting section.

According to this connection structure for electrical componentassembly, the terminal supporting section is formed in such a mannerthat the bent portions of the connection terminal sections are includedinside the bobbin. Thus, in a state that the strength of the bentportions is improved, the connection terminal sections are formedintegrally with the bobbin.

Further, in the connection structure for electrical component assembly,in the housing, a wire bonding section electrically connected by wirebonding to electrical components accommodated in the housing may beprovided at a position near the electrical component assembly, and inthe wire bonding section, a portion opposite to a connection partbetween the electrically conductive members and the housing-sideconnection terminals may be provided with a gap that permitsaccommodation and movement of a tip part of an electrical connection jigused for electrical connection of these.

According to this connection structure for electrical componentassembly, in the wire bonding section provided at a position near theelectrical component assembly in the housing, the portion opposite tothe connection part between the electrically conductive members and thehousing-side connection terminals in the electrical component assemblyis provided with a gap that permits insertion and movement of the tippart of the electrical connection jig used for electrical connection ofthese. Thus, the tip part of the electrical connection jig can beinserted through this gap so that the tip part of the electricalconnection jig can appropriately be arranged on a side of the connectionpart between the electrically conductive members and the housing-sideconnection terminals. Then, the tip part of the electrical connectionjig can be moved within the gap so that electrical connection work canbe performed appropriately.

Thus, in a state that a certain space used for insertion and movement ofthe tip part of the electrical connection jig is ensured in the housing,size reduction of the housing is achieved.

Further, at the time of electrical connection, when the tip part of theelectrical connection jig is inserted toward the gap, the tip part ofthe electrical connection jig can easily be arranged on a side of theconnection part between the electrically conductive members and thehousing-side connection terminals. This improves workability in theelectrical connection work.

Further, the wire bonding section can be arranged close to theelectrical component assembly. This improves cabling easiness of theelectrically conductive materials and flexibility in the design of thehousing.

Further, the connection structure for electrical component assembly mayfurther comprise a plurality of electrical component assemblies, thehousing may cover the plurality of the electrical component assemblies,the plurality of electrical component assemblies may be arranged in tworows, and in each row, pairs of the electrically conductive members oftwo of the electrical component assemblies may face each other.

According to this connection structure for electrical componentassembly, welding locations between the electrically conductive membersand the housing-side connection terminals are collected into a partbetween two electrical component assemblies in each row. Thus, even in aconnection structure having a plurality of electrical componentassemblies, the cycle time can be reduced in the electrical connectionwork. This improves productivity.

Further, in the connection structure for electrical component assembly,the housing may have an intermediate wall for dividing a space in thehousing into two, and that the intermediate wall may have: an openinghaving an approximately quadrangular shape and capable of accommodatinga plurality of the electrical component assemblies; an extension sectionextending from an edge of the opening to the opening; and a holdingsection that is provided in the extension section and against which anend of the electrical component assembly abuts so as to be positioned.

According to this connection structure for electrical componentassembly, the intermediate wall of the housing is provided with theopening having an approximately quadrangular shape and capable ofaccommodating a plurality of electrical component assemblies. Further,the extension section extending in the opening from the edge of theopening is provided with the holding section against which the end ofthe electrical component assembly abuts so that positioning is achieved.Thus, a plurality of electrical component assemblies can be arrangedinto the opening in such a way that the end of each electrical componentassembly abuts against the holding section so that positioning isachieved.

Further, the large opening is provided that is capable of accommodatinga plurality of electrical component assemblies. Thus, the amount ofmaterial such as resin material used in the intermediate wall can bereduced as much as possible. Thus, weight reduction of the housing isachieved.

Further, in the configuration that the extension section bridges themutually opposing edges of the opening, the electrical componentassembly can abut compactly and effectively with desired strength.

Further, in the connection structure for electrical component assembly,the electrical component assembly may have an end piece protruding andformed in the end, and is the holding section may be provided with anotch with which the end piece is engaged.

According to this connection structure for electrical componentassembly, when the electrical component assembly is to be arranged intothe opening, the end piece of the electrical component assembly isengaged with the notch provided in the holding section so that theelectrical component assembly is positioned to the opening. Thus,positioning of the electrical component assembly is achieved easily, andso is the assembling work. This contributes to improvement ofproductivity.

Further, in the connection structure for electrical component assembly,the extension section may have a reinforcement rib protruding in an axisdirection of the electrical component assembly.

According to this connection structure for electrical componentassembly, the reinforcement rib is provided in the extension section.Thus, in spite of the structure that the extension section bridges overthe opening, its strength is ensured so that the extension section canappropriately position and hold the electrical component assembly.Further, the reinforcement rib protrudes in the axis direction of theelectrical component assembly and hence can be arranged, for example, byusing a space formed between adjacent electrical component assemblies.This realizes space-saving.

Further, in the connection structure for electrical component assembly,in the extension section, the housing-side connection terminals may beformed by insert molding.

According to this connection structure for electrical componentassembly, in a state that the electrical component assembly ispositioned, the housing-side connection terminals can be arranged nearthe connection terminals of the electrical component assembly. Thus, aconnection structure for electrical component assembly is obtained inwhich space-saving is achieved and electric connection is easilyperformed between the housing-side connection terminals and theconnection terminals of the electrical component assembly.

Further, in the connection structure for electrical component assembly,in the extension section, the housing-side connection terminals may beinserted in a middle part in the extension direction.

According to this connection structure for electrical componentassembly, the amount of use of resin material is reduced as much aspossible by the amount corresponding to the presence of the housing-sideconnection terminals. Thus, weight reduction of the housing is achieved.

Further, the hydraulic pressure control apparatus according to thepresent invention has: a base; a solenoid valve arranged on one face ofthe base; the electrical component assembly mounted on the solenoidvalve; and a housing that is mounted on the one face of the base andthat accommodates the electrical component assembly and a control unit.

According to this hydraulic pressure control apparatus, in a state thata certain space used for insertion of the tip part of the electricalconnection jig is ensured in the housing, size reduction is achieved.

Further, the method for producing electrically conductive memberaccording to the present invention is a method for producing a pair ofelectrically conductive members assembled into an electrical componentassembly provided with a coil, wherein the pair of electricallyconductive members are manufactured by: forming connection terminalsections provided in the pair of electrically conductive members byarranging them alternately opposite to each other and then performingpress punching; and after the press punching, bending the connectionterminal sections in the pair of electrically conductive members towarda side departing from the coil into a protruding form.

According to this method for producing electrically conductive member,the layout on the metal plate is such that the connection terminalsections of the electrically conductive members are located alternatelyopposite to each other. This minimizes unnecessary parts after the presspunching. Thus, in comparison with the conventional art, a loss in thematerial is reduced and the production yield is improved. This realizescost reduction and improves the manufacturing efficiency.

Further, in the electrical component assembly having a pair ofelectrically conductive members produced as described here, incomparison with a case that the electrically conductive members risealong the axis direction of the coil like in the conventional art, thesize is reduced in the axis direction of the electrical componentassembly which is equal to the axis direction of the coil. Thus, sizereduction is achieved in a housing into which an electrical componentassembly is assembled and in an assembled apparatus to which thishousing is assembled like a vehicle brake hydraulic pressure controlapparatus.

Further, the method for producing electrically conductive member mayinclude, after the bending into a protruding form, as a resin moldingstep, including by insert molding the bent portion of the connectionterminal sections into the terminal supporting section provided in abobbin around which the coil is wound. Then, by virtue of the resinmolding step, the connection terminal sections are formed integrallywith the bobbin.

According to this method for producing electrically conductive member,by virtue of the resin molding step, the connection terminal sectionsare formed integrally with the bobbin in a manner that the bent portionsof the connection terminal sections are in a state of inclusion. Thus,in a state that the strength of the bent portions is improved, theconnection terminal sections are provided integrally with the bobbin.Thus, the bobbin with which the connection terminal sections are formedintegrally can be formed efficiently.

According to a first aspect of the present invention, size reduction isachieved in an assembled apparatus on which the electrical componentassembly is mounted. Further, the production yield is improved so thatthe manufacturing efficiency is improved.

A second object of the present invention is to provide a connectionstructure for electrical component assembly and a hydraulic pressurecontrol apparatus in which in a state that a certain space used forinsertion of the tip part of the electrical connection jig is ensured inthe housing, size reduction is achieved.

With the second object in mind, there is provided a connection structurefor electrical component including an electrical component assemblyprovided with a coil energized through a pair of electrically conductivemembers and with a housing that accommodates the electrical componentassembly and electrical components, wherein in the housing, providedare: a wire bonding section that is provided at a position near theelectrical component assembly and that is electrically connected to theelectrical components by wire bonding; and housing-side connectionterminals electrically connected to the pair of electrically conductivemembers, and in the wire bonding section, a portion opposite to aconnection part between the electrically conductive members and thehousing-side connection terminals is provided with a gap that permitsinsertion and movement of a tip part of an electrical connection jigused for electrical connection of these.

According to this connection structure for electrical componentassembly, in the wire bonding section provided at a position near theelectrical component assembly in the housing, the portion opposite tothe connection part between the electrically conductive members and thehousing-side connection terminals in the electrical component assemblyis provided with a gap that permits insertion and movement of the tippart of the electrical connection jig used for electrical connection ofthese. Thus, the tip part of the electrical connection jig can beinserted through this gap so that the tip part of the electricalconnection jig can appropriately be arranged on a side of the connectionpart between the electrically conductive members and the housing-sideconnection terminals. Then, the tip part of the electrical connectionjig can be moved within the gap so that electrical connection work canbe performed appropriately.

Thus, in a state that a certain space used for insertion and movement ofthe tip part of the electrical connection jig is ensured in the housing,size reduction of the housing is achieved.

Further, at the time of electrical connection, when the tip part of theelectrical connection jig is inserted toward the gap, the tip part ofthe electrical connection jig can easily be arranged on a side of theconnection part between the electrically conductive members and thehousing-side connection terminals. This improves workability in theelectrical connection work.

Further, the wire bonding section can be arranged close to theelectrical component assembly. This improves cabling easiness of theelectrically conductive materials and flexibility in the design of thehousing.

Further, in the connection structure for electrical component assembly,a plurality of the electrical component assemblies may be accommodatedin the housing, wherein, in adjacent ones of the electrical componentassemblies, the pairs of electrically conductive members may extend in adirection of facing each other and may be arranged opposing to eachother and may be respectively connected to the housing-side connectionterminals arranged in a direction perpendicular to the direction offacing each other, and that the gap may be located in the perpendiculardirection.

According to this connection structure for electrical componentassembly, the locations of welding between the electrically conductivemembers and the housing-side connection terminals are collected intoone. Further, at the time of electrical connection, one gap can be usedas a shared workspace for plurality of electrical component assemblies.

Thus, it is sufficient that gaps are provided in a minimal number, andhence an increase is obtained in the space efficiency. This permits sizereduction of the housing.

Further, in the connection structure for electrical component assembly,the plurality of electrical component assemblies may be arranged in tworows in the housing, and in each row, pairs of the electricallyconductive members of two of the electrical component assemblies mayface each other.

According to this connection structure for electrical componentassembly, the locations of welding between the electrically conductivemembers and the housing-side connection terminals can be collected intoa location between the electrical component assemblies. Thus, even in aconnection structure having a plurality of electrical componentassemblies, the cycle time can be reduced in the electrical connectionwork. This improves productivity.

Further, in the connection structure for electrical component assembly,the electrical component assembly may be an electrical componentassembly to be mounted on a vehicle, and that the electrical componentassembly may be accommodated in the housing in such a manner that at thetime of mounting on a vehicle, the pair of electrically conductivemembers are arranged in parallel with spacing in a direction equal to avertical direction of the vehicle.

According to this connection structure for electrical componentassembly, at the time of mounting on a vehicle, the pair of electricallyconductive members are arranged in parallel with spacing in a directionequal to the vertical direction of the vehicle. Thus, the electricalcomponent assembly has resistance against vibrations in the verticaldirection of the vehicle.

The hydraulic pressure control apparatus according to the presentinvention includes: a base; a solenoid valve arranged on one face of thebase; the electrical component assembly mounted on the solenoid valve;and the housing that is mounted on the one face of the base and thataccommodates a control unit including the electrical component assemblyand the electrical components.

According to this hydraulic pressure control apparatus, in a state thata certain space used for insertion of the tip part of the electricalconnection jig is ensured in the housing, size reduction is achieved.

According to a second aspect of the present invention, a connectionstructure for electrical component assembly and a hydraulic pressurecontrol apparatus are obtained in which in a state that a certain spaceused for insertion of the tip part of the electrical connection jig isensured in the housing, size reduction is achieved.

A third object of the present invention is to provide a hydraulicpressure control apparatus including a housing provided with anintermediate wall in which weight reduction of the housing is achievedso that the amount of use of resin material in the intermediate wall isreduced as much as possible.

With the third object in mind, there is provided a hydraulic pressurecontrol apparatus including: a base; a solenoid valve arranged on oneface of the base; an electrical component assembly mounted on thesolenoid valve; and a housing that is mounted on the one face of thebase and that accommodates the electrical component assembly and acontrol unit, wherein the housing includes an intermediate wall fordividing an inner space thereof into two, and wherein the intermediatewall includes: an opening having an approximately quadrangular shape andcapable of accommodating a plurality of the electrical componentassemblies; an extension section extending such as to bridge mutuallyopposing edges of the opening; and a holding section that is provided inthe extension section and against which an end of the electricalcomponent assembly abuts so as to be positioned.

According to this hydraulic pressure control apparatus, the intermediatewall of the housing is provided with the opening having an approximatelyquadrangular shape and capable of accommodating a plurality ofelectrical component assemblies. Further, the extension sectionextending over the mutually opposing edges of the opening is providedwith the holding section against which the end of the electricalcomponent assembly abuts so that positioning is achieved. Thus, aplurality of electrical component assemblies can be arranged into theopening in such a way that the end of each electrical component assemblyabuts against the holding section so that positioning is achieved.

Further, the large opening is provided that is capable of accommodatinga plurality of electrical component assemblies. Thus, the amount ofmaterial such as resin material used in the intermediate wall can bereduced as much as possible. Thus, weight reduction of the housing isachieved.

Further, in the hydraulic pressure control apparatus, the electricalcomponent assembly may have an end piece protruding and formed in theend, and the holding section is provided with a notch with which the endpiece is engaged.

According to this hydraulic pressure control apparatus, when theelectrical component assembly is to be arranged into the opening, theend piece of the electrical component assembly is engaged with the notchprovided in the holding section so that the electrical componentassembly can easily and reliably be positioned into the opening. Thus,positioning of the electrical component assembly is achieved easily, andso is the assembling work. This contributes to improvement ofproductivity.

Further, in the hydraulic pressure control apparatus, the extensionsection may have a reinforcement rib protruding in an axis direction ofthe electrical component assembly.

According to this hydraulic pressure control apparatus, thereinforcement ribs are provided in the extension section. Thus, in spiteof the structure that the extension section bridges over the opening,its strength is ensured so that the extension section can appropriatelyposition and hold the electrical component assembly. Further, thereinforcement ribs protrude in the axis direction of the electricalcomponent assembly and hence can be arranged, for example, by using aspace formed between adjacent electrical component assemblies. Thisrealizes space-saving.

Further, the present invention is characterized in that the edge of theopening opposite to the holding section is provided with an edge-sideholding section against which the other end of the electrical componentassembly abuts so that positioning is achieved.

According to this hydraulic pressure control apparatus, the electricalcomponent assembly is positioned and held at least at two locationsconsisting of the holding section and the edge-side holding section ofthe extension section. Thus, positioning of the electrical component toassembly is easily achieved. Further, more stable holding of theelectrical component assembly is achieved by necessary minimum use ofresin material.

Further, in the extension section, insert molding of the housing-sideconnection terminals on the housing side may be performed. According tothis configuration, in a state that the electrical component assembly ispositioned, the housing-side connection terminals can be arranged nearthe connection terminals of the electrical component assembly. Thus, aconnection structure for electrical component assembly is obtained inwhich space-saving is achieved and electric connection is easilyperformed between the housing-side connection terminals and theconnection terminals of the electrical component assembly.

Further, in the extension section, the housing-side connection terminalsmay be inserted in a middle part in the extension direction. Accordingto this configuration, the amount of use of resin material is reduced asmuch as possible by the amount corresponding to the presence of thehousing-side connection terminals. Thus, weight reduction of the housingis achieved.

According to a third aspect of the present invention, a hydraulicpressure control apparatus is obtained which includes a housing providedwith an intermediate wall and in which weight reduction of the housingis achieved so that the amount of use of resin material in theintermediate wall is reduced as much as possible.

BRIEF DESCRIPTION OF THE DRAWINGS

A general configuration that implements the various features of theinvention will be described with reference to the drawings. The drawingsand the associated descriptions are provided to illustrate embodimentsof the invention and should not limit the scope of the invention.

FIG. 1 is a sectional view showing a vehicle brake hydraulic pressurecontrol apparatus serving as an example of a hydraulic pressure controlapparatus to which a connection structure for electrical componentassembly according to a first embodiment of the present invention isapplied.

FIGS. 2A and 2B are views of a housing viewed obliquely from frontbelow. FIG. 2A is a perspective view in a state that an electricalcomponent assembly is mounted. FIG. 2B is a perspective view in a statebefore an electrical component assembly is mounted.

FIG. 3 is an enlarged perspective view showing a connected state betweenelectrically conductive members and housing-side connection terminals.

FIGS. 4A and 4B are views of a housing viewed from front. FIG. 4A is afront view in a state that an electrical to component assembly ismounted. FIG. 4B is a front view in a state before an electricalcomponent assembly is mounted.

FIGS. 5A and 5B are sectional views of a housing. FIG. 5A is a sectionalview taken along line Va-Va in FIG. 4A. FIG. 5B is a sectional viewtaken along line Vb-Vb in FIG. 4A (shown in a state that the forward andrearward directions are in conformity with those of FIG. 5A).

FIGS. 6A and 6B are views showing an electrical component assembly. FIG.6A is a perspective view viewed from one side of the electricallyconductive member. FIG. 6B is a perspective view viewed from theopposite side of the electrically conductive member.

FIGS. 7A to 7D are views showing an electrical component assembly. FIG.7A is a plan view. FIG. 7B is a side view. FIG. 7C is a front view. FIG.7D is a rear view.

FIG. 8A is a layout view related with punching of electricallyconductive members (a press-punched component) in an electricalcomponent assembly according to an embodiment. FIG. 8B is a layout viewrelated with punching of electrically conductive members (apress-punched component) according to a comparison example.

FIGS. 9A and 9B are explanation views showing a step of electricalconnection between the electrically conductive members and thehousing-side connection terminals.

FIGS. 10A and 10B are explanation views showing a step of electricalconnection between the electrically conductive members and thehousing-side connection terminals.

FIGS. 11A and 11B are views showing a housing of a vehicle brakehydraulic pressure control apparatus serving as an example of ahydraulic pressure control apparatus to which a connection structure forelectrical component assembly according to a second embodiment of thepresent invention is applied. FIG. 11A is a view of a housing viewedobliquely from front below. FIG. 11B is a sectional view taken alongline XIb-XIb in FIG. 11A.

FIG. 12A is a view of a housing viewed obliquely from rear below in astate before an electrical component assembly is mounted. FIG. 12B is aview of a housing viewed obliquely from rear below in a state that anelectrical component assembly is mounted.

DETAILED DESCRIPTION OF THE EMBODIMENT(S)

The mode of implementing the present invention is described below indetail with reference to the accompanying drawings. Here, in thedescription, like components are designated by like numerals, and henceduplicated description is omitted.

First Embodiment

As shown in FIG. 1, a vehicle brake hydraulic pressure control apparatus(referred to as a “brake control apparatus”, hereinafter) U serving asan example of a hydraulic pressure control apparatus on which anelectrical component assembly 20 according to the present embodiment ismounted is used suitably in a vehicle such as a motorcycle, a motortricycle, an all terrain vehicle (ATV), and an automobile so as tocontrol appropriately a damping force (a brake fluid pressure) appliedon the wheels of the vehicle. The following description is given for anexample that the brake control apparatus U is applied to a motorcycle.However, the type of a vehicle on which the brake control apparatus U ismounted is not limited to this.

The brake control apparatus U has: a base 1; solenoid valves 2 and 3arranged on one face 1 a of the base 1; an electrical component assembly20 mounted on the solenoid valves 2 and 3; a housing 10 mounted on theone face 1 a of the base 1; and a control unit (electrical component) 40accommodated in the housing 10. Further, on a rear face 1 b serving asthe rear side of the one face 1 a of the base 1, an electric motor 60 isarranged for driving a pump (not shown).

Here, in the following description, directions relative to the housing10 are defined as shown in FIG. 1.

In the connection structure for the electrical component assembly 20according to the present embodiment, the electrical component assembly20 arranged on the one face 1 a of the base 1 in an orientationperpendicular to the one face 1 a of the base 1 is electricallyconnected to the housing 10 mounted on the one face 1 a of the base 1 ina manner of covering the electrical component assembly 20. Further,electrically conductive members 30A and 30B protruding from theelectrical component assembly 20 are electrically connected tohousing-side connection terminals 16 protruding from the housing 10.

The base 1 is a metal member formed in an approximately rectangularparallelepiped shape. In its inside, a passage R for brake fluid isformed. In the one face 1 a of the base 1, attaching holes 2 a and 3 aused for attaching the solenoid valves 2 and 3 are formed.

The housing 10 is constructed from: a housing body 11 formed from resinin the shape of an approximately rectangular pipe; and a lid (not shown)mounted on a step 12 formed in the front end opening of the housing body11. The housing body 11 is attached to the one face 1 a of the base 1 byusing fastening members such as attaching screws. Here, the lid is fixedto the front end opening of the housing body 11 by adhesives, welding,or the like.

In the inside of the housing body 11, an intermediate wall 13 is formedin which a part of the housing-side connection terminals 16 areembedded. The intermediate wall 13 serves as a partition for dividingthe inside of the housing 10 into a first accommodation chamber 11A thatopens toward the base 1 side and a second accommodation chamber 11B thatopens toward the counter-base-1 side.

The first accommodation chamber 11A accommodates the electricalcomponent assembly 20 to be mounted on the solenoid valves 2 and 3. Thesecond accommodation chamber 11B accommodates a control unit 40. Here,the control unit is an electronic board on which a large number ofelectronic components for control are mounted.

In the inside of the housing 10, as indicated by a dotted line in FIG.2B, an opening 14 having an approximately quadrangular shape is providedin the intermediate wall 13 (in FIG. 2B, the corners of the opening 14are shown in rounded shapes). In the opening 14, four electricalcomponent assemblies 20 in total can be arranged (see FIG. 2A). In thepresent embodiment, the electrical component assemblies 20 are held bythe opening 14 and arranged in two rows in the up and down directions ofthe housing body 11. Then, in each row, pairs of electrically conductivemembers 30A and 30B of two electrical component assemblies 20 and 20 arearranged such as to face each other in the right and left directions.

Further, the housing-side connection terminals 16 and are arranged in adirection perpendicular to the direction that the pairs of electricallyconductive members 30A and 30B face each other.

Further, the electrical component assemblies 20 are accommodated in thehousing body 11 in such a manner that the pairs of electricallyconductive members 30A and 30B are arranged in parallel with spacing ina direction equal to the up and down directions of a vehicle (that is,the pairs of electrically conductive members 30A and 308 are arranged ina direction equal to the vertical direction of a vehicle, when mountedon a vehicle).

In the opening 14, as shown in FIG. 4B, an extension section 17 extendssuch as to bridge the mutually opposing edges 13 a and 13 b of theopening 14. Thus, the opening 14 is divided up and down by theintermediate wall 13 and the extension section 17, into two longitudinalholes 14 a and 14 b provided in parallel in the up and down directionsas shown in FIGS. 2A and 2B. Here, as shown in FIG. 2A, into each of thelongitudinal holes 14 a and 14 b, a pair (two pieces) of electricalcomponent assemblies 20 and 20 are mounted from the rear face side ofthe housing 10 (from the first accommodation chamber 11A side) in such amanner that the electrical component assemblies 20 and 20 are arrangedadjacent to each other with spacing in the right and left directions.

In the extension section 17, the opening edge of each of thelongitudinal holes 14 a and 14 b is provided with a holding section 15Afor holding one end of the electrical component assembly 20 (see FIG.4B). The holding section 15A protrudes from the extension section 17toward the inside of each of the longitudinal holes 14 a and 14 b. Then,the holding section 15A abuts against and holds one end of the upper endwall 21 of the electrical component assembly 20 inserted from the firstaccommodation chamber 11A side.

On the other hand, the opening edge of each of the longitudinal holes 14a and 14 b (the intermediate walls 13 and 13) located on a side oppositeto the side where the holding section 15A is provided is provided withan edge-side holding section 15B. The edge-side holding section 15Bprotrudes from the opening edge of each of the longitudinal holes 14 aand 14 b toward the inside of each of the longitudinal holes 14 a and 14b. Then, the edge-side holding section 15B abuts against and holds oneend of the upper end wall 21 of the electrical component assembly 20inserted from the first accommodation chamber 11A side.

That is, one end of the upper end wall 21 abuts against the holdingsection 15A and the other end of the upper end wall 21 abuts against theedge-side holding section 15B, so that the electrical component assembly20 is positioned and mounted in the housing 10 in such a manner thatpositioning is performed at least at the two locations.

Here, as shown in FIG. 4B, in the holding section 15A and the edge-sideholding section 15B, a notch 15 c is formed, to which an end piece 23 a(see FIG. 6A, the same in the following) protruding and formed in theend of the electrical component assembly 20 is engaged. The notch 15 chas an approximately quadrangular shape with which the end piece 23 a ofthe electrical component assembly 20 can be engaged.

As shown in FIGS. 2A and 4A, in the second accommodation chamber 11B,the wall 11 a of the housing body 11 located near the electricalcomponent assembly 20 is provided with a wire bonding section 18 aelectrically connected to the control unit 40 (see FIG. 1, the same inthe following) by wire bonding. (not shown). The wire bonding section 18a is a part where a plurality of terminals are arranged in parallel inan exposed state. The plurality of terminals are electrically connectedthrough wires to terminals (not shown) provided on the control unit 40side. In the present embodiment, the control unit 40 is mounted alongthe wire bonding section 18 a and the wire bonding section 18 b and onthe inner side of them. That is, the control unit 40 is mounted such asto overlap, with spacing, with the electrical component assembly 20arranged in the opening 14.

In the wire bonding section 18 a, a portion opposite to a connectionpart between the electrically conductive members 30A (30B) and thehousing-side connection terminals 16 is provided with a gap 19. The gap19 is located in a direction perpendicular to the direction where thepair of electrically conductive members 30A and 30B face each other (ina direction where the pair of electrically conductive members 30A and30B and the housing-side connection terminals 16 and 16 overlap witheach other). Further, the gap 19 is formed in a size that permitsinsertion and movement of the tip part 51 (see FIGS. 9A and 9B), thesame in the following) of the electrical connection jig 50 (see FIGS. 9Aand 9B, the same in the following), and is feasible as a work space atthe time of electrical connection between the electrically conductivemembers 30A (30B) and the housing-side connection terminals 16.

As shown in FIGS. 4A and 4B, the gap 19 is formed in a size that permitselectrical connection to the two housing-side connection terminals 16and 16 arranged in the edge of longitudinal hole 14 a (14 b) (in a sizehaving a sufficient depth reaching the opposing part between thehousing-side connection terminals 16 and 16 and the electricallyconductive members 30A (30B)). Then, the gap 19 is feasible as a sharedspace at the time of electrical connection between the housing-sideconnection terminals 16 and 16 and the electrically conductive members30A (30B). In the gap 19, its front side (the upper part in the page ofFIG. 5A) is opened and its rear side (the lower part in the page of FIG.5A) is a bottom. Then, on the bottom side, the housing-side connectionterminals 16 and 16 and the electrically conductive members 30A (30B)are arranged in a mutually opposing manner. That is, the housing-sideconnection terminals 16 and 16 and the electrically conductive members30A (30B) are located on the rear side relative to the control unit 40.

As described above, as shown in FIG. 3, the pair of electrical componentassemblies 20 arranged in the longitudinal hole 14 a (14 b) are arrangedin a state that the sides in each of which the electrically conductivemembers 30A and 30B are provided are facing each other. Then, in thelongitudinal hole 14 a (14 b), a gap is formed between the pair ofelectrical component assemblies 20 and 20. Then, in the gap, theelectrically conductive materials 16B extending from the edge side ofthe opening 14 in the up and down directions are exposed. Then, the endsof the electrically conductive materials 16B are bent so that thehousing-side connection terminals 16 are formed. Then, in each of thehousing-side connection terminals 16, the connection terminal sections30 a and 30 b of the electrically conductive members 30A and 30B arearranged in a crossed state (in an orthogonal state). That is, theconnection terminal sections 30 a and 30 b extend in a directionperpendicular to the direction where it is provided with the electricalcomponent assemblies 20 are arranged in the opening 14 (the longitudinalholes 14 a and 14 b). Further, the lengths of the connection terminalsections 30 a and 30 b are set such that welding with the correspondinghousing-side connection terminals 16 is allowed and such that theconnection terminal sections 30 a and 30 b are located in a directionperpendicular to the direction where the pair of electrically conductivemembers 30A and 30B face each other on a side of the housing-sideconnection terminals 16.

On the other hand, a large part of the electrically conductive materials16B are embedded in the housing body 11 or the intermediate wall 13.Then, as shown in FIGS. 2B and 3, the electrically conductive materials16B protrude into the longitudinal holes 14 a and 14 b from the openingedges (the edges) of the longitudinal holes 14 a and 14 b in theintermediate wall 13, and then are bent toward the inside of the secondaccommodation chamber 11B so as to constitute the housing-sideconnection terminals 16. Here, as described later, the connectionterminal sections 30 a and 30 b of the electrical component assembly 20are arranged at a position deviated in the axis direction (see FIG. 6A)of the electrical component assembly 20. Then, the housing-sideconnection terminals 16 are arranged in correspondence to thisdeviation.

Further, as shown in FIGS. 2B and 4B, in the extension section 17arranged between the one longitudinal hole 14 a and the otherlongitudinal hole 14 b, the electrically conductive members 16A isexposed in a manner of bridging the left and the right holding sections15A and 15A of the extension section 17. Then, the housing-sideconnection terminals 16 are provided toward the longitudinal holes 14 aand 14 b. In the present embodiment, the housing-side connectionterminals 16 (the electrically conductive members 16A) are insert-moldedinto the extension section 17. Thus, in the middle part of the extensiondirection of the extension section 17, the housing-side connectionterminals 16 (the electrically conductive members 16A) are inserted sothat the extension section 17 bridges over the opening 14 via theelectrically conductive members 16A.

As shown in FIGS. 6A and 6B, the electrical component assembly 20 is acoil device for opening and closing the solenoid valves 2 and 3 (seeFIG. 1) when energized, and has: a yoke 21A; a bobbin 25 arranged in theyoke 21A; a coil 27 wound around the bobbin 25; and the electricallyconductive members 30A and 30B. As shown in FIG. 1, the electricalcomponent assembly 20 is an electrical component accommodated in thehousing 10 in a state of surrounding the solenoid parts of the solenoidvalves 2 and 3, and is a magnetic coil for generating a magnetic fieldaround the solenoid valves 2 and 3 (see FIG. 1) when the coil 27 shownin FIGS. 6A and 6B is energized from the housing-side connectionterminals 16 and 16 through the connection terminal sections 30 a and 30b.

The yoke 21A, is formed from a metallic material having magnetism.Further, as shown in FIG. 6B, the yoke 21A is a component having theshape of a rectangular pipe provided with an upper end wall 21, a lowerend wall 22, and left and right side walls 23 and 23, and is magneticmaterial for improving the magnetic efficiency of the coil 27. Each ofthe upper end wall 21, the lower end wall 22, and the two side walls 23and 23 forms a rectangular wall surface. Then, the space surrounded bythe upper end wall 21, the lower end wall 22, and the two side walls 23and 23 accommodates the bobbin 25.

Here, the upper end wall 21 serves as an abutting surface that abutsagainst the holding section 15A and the edge-side holding section 15B.

In the present embodiment, a bent plate member having a U-shapeconstituting the lower end wall 22 and the two side walls 23 and 23 iscombined with the upper end wall 21 having a flat plate shape, and thenthe end pieces 23 a and 23 a of the two side walls 23 and 23 are fixedto the upper end wall 21 so that the yoke 21A is constructed.

Further, a circular hole 21 a is formed in the center part of the upperend wall 21, and a hole (not shown) of the same size is formed also inthe center part of the lower end wall 22.

As shown in FIGS. 7B, 7C, and 7D, the bobbin 25 is a resin componentprovided with a cylinder section 24 and flanges 25 a and 25 b formed atboth of the up and down ends of the cylinder section 24. The center partof the bobbin 25 is provided with a circular center hole 24 a (see FIG.7A) which is a through hole.

The bobbin 25 is accommodated in the yoke 21A. Then, the upper flange 25a is attached to the lower face of the upper end wall 21, and the lowerflange 25 b is attached to the upper face of the lower end wall 22. Thecenter hole 24 a of the bobbin 25 is in communication with the hole 21 aof the upper end wall 21 and a hole (not shown) of the lower end wall22.

In the present embodiment, as shown in FIG. 7A, the upper flange 25 a ofthe bobbin 25 protrudes in a radial direction of the bobbin 25 relativeto the upper end wall 21 of the yoke 21A.

Further, in the upper flange 25 a, in a portion protruding rearwardrelative to the upper end wall 21, that is, at the end (rearward) of theupper end wall 21, a terminal supporting section 26 (a resin part) isformed where the pair of electrically conductive members 30A and 30B areformed integrally. The terminal supporting section 26 has square-shapedprotruding sections 26 a and 26 b. Then, the center parts (the bentportions serving as resin embedded sections 31 c and 31 c) of the pairof electrically conductive members 30A and 30B are embedded (included)into these protruding sections 26 a and 26 b by insert molding.

As shown in FIGS. 6A, 6B, and 7A to 7D, the pair of electricallyconductive members 30A and 30B are bar-shaped metal components whosecenter parts are embedded in the protruding sections 26 a and 26 b ofthe terminal supporting section 26. The pair of electrically conductivemembers 30A and 30B have left and right symmetrical shapes having only adifference between the positions where the connection terminal sections30 a and 30 b are provided (the position in the axis direction of theelectrical component assembly 20). Thus, the following description isgiven for the one electrically conductive member 30A, and theelectrically conductive member 30B is described only when necessary.

As shown in FIG. 7A, the electrically conductive members 30A has anapproximately L-shape in plan view. Then, the center part serving as theresin embedded section 31 c is embedded in the protruding section 26 a.More specifically, the electrically conductive member 30A has: anextending section 31 extending leftward in the figure along the rearface (the face on which the electrically conductive member 30A isprovided) of the electrical component assembly 20; and a connectionterminal section 30 a protruding rearward from the rear face similarlyin a direction perpendicular to the rear face. Here, in the electricallyconductive member 30B, the center part serving as the resin embeddedsection 31 c is embedded in the protruding section 26 b, and theextending section 31 extends in the right direction in the figure.

On the other hand, the extending sections 31 and the connection terminalsections 30 a and 30 b extend in a direction along the intermediate wall13 (see FIGS. 3 and 5A; in a direction perpendicular to the axisdirection of the electrical component assembly 20).

The extending section 31 has: a wire connection section 36 to which awire (not shown) from the coil 27 is electrically connected; and awinding section 34 which is formed on the end side relative to the wireconnection section 36 and around which a tip part of the wire is wound.

The wire connection section 36 is composed of a tongue piece that can bebent toward the rear face side of the extending section 31 (FIGS. 6A to7D show a state of being bent). Then, a wire (not shown) is pinched andwelded in the inner side of the bent so that electrical connection ofthe wire is achieved. As shown in FIGS. 7C and 7D, the winding section34 is provided by forming wedge-shaped cuts in the extending section 31in the up and down directions. Then, the wire is wound around thewedge-shaped cut parts.

Here, on a side of the winding section 34, a guide piece 35 for guidingthe wire to the winding section 34 is formed in a manner of risingupward.

In the approximately center part (the resin embedded section 31 c) ofthe electrically conductive member 30A, the connection terminal section30 a is bent by 90 degrees in a direction departing from the electricalcomponent assembly 20, and protrudes rearward from the rear face of theelectrical component assembly 20 as described above. The connectionterminal section 30 a has a thinner shape than the extending section 31,and is elastically deformable.

In the present embodiment, the electrically conductive members 30A and30B may be constructed in the form of a hoop terminal, that is, may bemanufactured in the form of an assembled component in which the resinembedded sections 31 c and 31 c are embedded in the protruding sections26 a and 26 b of the terminal supporting section 26 via a linkagesection 38 described later so that the electrically conductive members30A and 30B and the bobbin 25 are formed integrally with each other.

Such an assembled component is manufactured by a press punching step, abending processing step, a resin molding step, and a separation stepwhich are described below.

As shown in FIG. 8A, at the press punching step, a press-punchedcomponent 300 provided with electrically conductive plates 301A and 301Bserving as the sources of the electrically conductive members 30A and30B is obtained by press punching. At the press punching step, thepress-punched component 300 is obtained from a flat belt-shaped metalplate or the like having electrical conductivity and a certainthickness.

The press-punched component 300 has: a linkage section 303 having aframe shape and serving as a carrier; and electrically conductive plates301A and 301B formed continuously to the linkage section 303 viaconnection sections 303 a and 303 b. These components are formed basedon the above-mentioned terminal structure.

The electrically conductive plates 301A and 301B have: tapered shapesections 304 to be formed into the winding sections 34; small protrudingpieces 305 to be formed into the guide pieces 35; protruding pieces 306to be formed into the wire connection sections 36; and extension pieces307 a and 307 b to be formed into the connection terminal sections 30 aand 30 b.

The guide pieces 35 and the protruding pieces 306 extend in the up anddown directions (in the transverse direction) of the linkage section303. Further, the extension pieces 307 a and 307 b extend in the rightand left directions (in the longitudinal direction) of the linkagesection 303.

The extension pieces 307 a and 307 b are arranged alternately in the upand down directions in the center part of the press-punched component300 in such a manner that overlapping is avoided. That is, the extensionpiece 307 a extends from the lower side of the center part of the base301 to be formed into the extending section 31, toward the extensionpiece 307 b side. Further, the extension piece 307 b extends from theupper side of the center part of the base 301 toward the extension piece307 a side. Thus, the extension pieces 307 a and 307 b are arrangedopposite to each other with spacing in the up and down directions in thecenter part of the press-punched component 300 in such a manner thatinterference with each other is avoided.

Then, at the bending processing step, bending processing is performed onthe protruding pieces 306 of the electrically conductive plates 301A and301B and on the extension pieces 307 a and 307 b (the center side partsof the bases 301). That is, the protruding pieces 306 are bent from themiddle part toward the base 301 side such as to become capable ofpinching a wire (not shown) (that is, bent such as to rise from theplate surface of the press-punched component 300 to the near side alongon the bending line T1, and then bent toward the lower direction of thepress-punched component 300 such as to face the upper face of the base301 like in the connection terminal sections 30 a and 30 b in FIG. 7A).Further, in such a manner that the extension pieces 307 a and 307 bprotrude at right angles relative to the plate surfaces of thepress-punched component 300, bending processing is performed on theextension pieces 307 a and 307 b along the bending lines T and T towardthe left and the right such as to rise from the plate surface of thepress-punched component 300 to the near side.

After that, at the resin molding step, insert molding is performed suchthat the bent portions of the extension pieces 307 a and 307 b areformed as the resin embedded sections 31 c and 31 c. In this insertmolding, the protruding sections 26 a and 26 b (the terminal supportingsection 26) are formed such as to include the bent portions, and thebobbin 25 is formed integrally with this.

After that, at the separation step, the connection sections 303 a areseparated so that the electrically conductive plates 301A and 301B areseparated from the linkage section 303. As a result, an assembledcomponent is obtained in which the resin embedded sections 31 c and 31 cof the electrically conductive members 30A and 30B are embedded in theprotruding sections 26 a and 26 b of the terminal supporting section 26of the bobbin 25.

Here, in the above-mentioned press-punched component 300, the region Ssurrounded by the linkage section 303, the left and right protrudingpieces 306 and 306, and the extension piece 307 b is discarded at theabove-mentioned press punching step. This region S is smaller thanregions S′ and S′ discarded in a press-punched component 300′ (see FIG.8B) according to the conventional art.

That is, in the conventional press-punched component 300′ shown in FIG.8B, extension pieces 307 a′ and 307 b′ to be formed into connectionterminal sections 30 a′ and 30 b′ extend (rise) in the up and downdirections (in the transverse direction). Thus, a linkage section 303′has a larger size in the up and down directions, and hence at the presspunching step, the punching need be performed in a larger size by thislength of the rise. Thus, at the press punching step, such largerregions S′ and S′ need be discarded.

In contrast, in the present embodiment, the extension pieces 307 a and307 b extend toward the right and left directions (in the longitudinaldirection) of the linkage section 303, and arranged alternativelyopposite to each other such as not to overlap in the up and downdirections. Thus, as shown in FIG. 8A, a length corresponding to therise of the protruding pieces 306 and 306 to be formed into the wireconnection sections 36 and 36 is sufficient in the up and downdirections (in the transverse direction). Thus, as described above, itis sufficient that a region S much smaller than the conventional regionsS′ and S′ is discarded at the press punching step.

Next, assembling of the electrical component assembly 20 into thehousing 10 is described below. At the time of assembling of theelectrical component assembly 20, the electrical component assembly 20is inserted from the first accommodation chamber 11A side of the housing10 such that the one end and the other end of the upper end wall 21 ofthe electrical component assembly 20 abut against the holding section15A and the edge-side holding section 15B of the longitudinal holes 14 aand 14 b of the intermediate wall 13. As a result, the connectionterminal sections 30 a and 30 b of the electrically conductive members30A and 30B are arranged on a side of the housing-side connectionterminals 16 (see FIGS. 2A, 3, and 5A).

Then, as shown in FIG. 9A, the pair of electrical connection jigs 50 and50 are moved from the second accommodation chamber 11B side (thecounter-base-1 side) of the housing 10 into the second accommodationchamber 11B such as that the tip part 51 of the one electricalconnection jig 50 is located in the gap 19 as shown in FIG. 9B. As aresult, for example, the connection part between the connection terminalsection 30 b of the electrically conductive member 30B and thehousing-side connection terminal 16 is pinched between the two tip parts51 and 51 in a non-contacting state. After that, as shown in FIG. 10A,the electrical connection jigs 50 and SO are made close to each othersuch that the two tip parts 51 and 51 pinches the connection terminalsection 30 b and the housing-side connection terminal 16.

In this state, an electric current is supplied through the electricalconnection jig 50 so that the electrically conductive member 30B and thehousing-side connection terminals 16 are welded (electrically connected)to each other. On completion of electrical connection between theelectrically conductive member 30B and the housing-side connectionterminals 16, pinching by the tip parts 51 and 51 is released so thatthe electrical connection jig 50 is moved in a right or left directionso as to be located at a position where the connection part between theconnection terminal section 30 a of the electrically conductive member30A in the adjacent electrical component assembly 20 and thehousing-side connection terminal 16 is pinched between the two tip parts51 and 51 in a non-contacting state similarly to the above-mentionedoperation. In this case, one tip part 51 is moved in the right and leftdirections in a state of being located within the gap 19 with using thespace in the gap 19. Further, with using the space formed between theconnection terminal section 30 a and the connection terminal section 30b, the other tip part 51 is moved in the right and left directions in astate of being located in this space. Then, after the movement, theconnection part between the connection terminal section 30 a of theelectrically conductive member 30A and the housing-side connectionterminal 16 is pinched and electrically connected by the two tip parts51 and 51 similarly to the above-mentioned operation.

After that, as shown in FIG. 10B, the connection part between theconnection terminal section 30 a of the electrically conductive member30A and the housing-side connection terminals 16 is pinched, and then anelectric current is supplied through the electrical connection jig 50 inthis state so that the electrically conductive member 30A and thehousing-side connection terminals 16 are welded (electrically connected)to each other.

Further, electrical connection between other electrically conductivemembers 30A and 30B and housing-side connection terminals 16 and 16 isperformed sequentially.

When electrical connection work has been completed for all electricallyconductive members 30A and 30B and housing-side connection terminals 16,the control unit 40 is attached to the housing 10 as shown in FIG. 1.Then, a lid (not shown) is attached so that the housing 10 is completed.After that, at steps similar to those of the conventional, various kindsof components such as the solenoid valves 2 and 3 and the housing 10 areattached to the base 1 so that the brake control apparatus U ismanufactured.

As described above, the connection terminal sections 30 a and 30 b ofthe pair of electrically conductive members 30A and 30B are bent towarda side departing from the coil so as to protrude toward the electricalcomponent assembly 20, and one connection terminal section 30 a isarranged at a position deviated in an axis direction of the coil 27relative to the other connection terminal section 30 b. Thus, incomparison with a case that the electrically conductive members risealong the axis direction of the coil 27 like in the conventional art,the size is reduced in the axis direction of the electrical componentassembly 20 which is equal to the axis direction of the coil 27. Thus,size reduction is achieved in the housing 10 into which the electricalcomponent assembly 20 is assembled and in the brake control apparatus Uhaving this housing 10.

Further, at the time of formation of the electrically conductive members30A and 30B from a metal plate or the like by press punching, theelectrically conductive members 30A and 30B are formed by press punchingby using a layout that the connection terminal sections 30 a and 30 b ofthe electrically conductive members 30A and 30B are located alternatelyopposite to each other on the metal plate. This minimizes unnecessaryparts after the press punching. Thus, in comparison with theconventional art, a loss in the material is reduced and the productionyield is improved. This realizes cost reduction and improves themanufacturing efficiency.

Further, the electrically conductive members 30A and 30B areelectrically connected in a crossing state to the housing-sideconnection terminals 16 provided in the intermediate wall 13 extendingin a direction parallel to the protruding direction of the electricallyconductive members 30A and 30B. Thus, the housing-side connectionterminals 16 are arranged on the housing 10 side in a space-savingmanner. Further, a situation is suppressed that the electricallyconductive members 30A and 30B protrude toward the housing 10 side.Thus, size reduction is achieved in the brake control apparatus U intowhich the electrical component assembly 20 is assembled.

Further, in the housing 10, the control unit 40 is allowed to bearranged close to the electrical component assembly 20. This increasesflexibility in the design.

Further, the connection terminal sections 30 a and 30 b are formed inthe bobbin 25 integrally in such a manner that the bent portions servingas the resin embedded sections 31 c and 31 c of the connection terminalsections 30 a and 30 b are included in the inside. Thus, in a state thatthe strength of the bent portions is improved, the connection terminalsections 30 a and 30 b can be provided integrally with the bobbin 25.Thus, the bobbin 25 with which the connection terminal sections 30 a and30 b are formed integrally can be formed efficiently.

The wire bonding section lea has the gap 19. Thus, the tip part 51 ofthe electrical connection jig 50 can be inserted through this gap 19.Thus, the tip part 51 of the electrical connection jig 50 canappropriately be arranged on a side of the connection part between theelectrically conductive members 30A (30B) and the housing-sideconnection terminals 16. Then, the tip part 51 of the electricalconnection jig 50 can be moved within the gap 19 so that electricalconnection work can be performed appropriately.

Thus, in a state that a certain space used for insertion and movement ofthe tip part 51 of the electrical connection jig 50 is ensured in thehousing 10, size reduction of the housing 10 is achieved.

Further, at the time of electrical connection, when the tip part 51 ofthe electrical connection jig 50 is inserted toward the gap 19, the tippart 51 of the electrical connection jig 50 can easily be arranged on aside of the connection part between the electrically conductive members30A (30B) and the housing-side connection terminals 16. This improvesworkability in the electrical connection work.

Further, the wire bonding section 18 a can be arranged close to theelectrical component assembly 20. This improves cabling easiness of theelectrically conductive materials 16B and flexibility in the design ofthe housing 10.

Further, the gap 19 is formed in a size that permits electricalconnection of the two housing-side connection terminals 16 and 16arranged in the edge of the longitudinal hole 14 a (14 b). Thus, the gap19 is feasible as a shared space at the time of electrical connectionbetween the housing-side connection terminals 16 and 16 and theelectrically conductive members 30A (30B). Thus, at the time ofelectrical connection, the tip part 51 of the electrical connection jig50 is move within the gap 19 to the position corresponding to the twohousing-side connection terminals 16 and 16 and then electricalconnection between the two housing-side connection terminals 16 and 16and the electrically conductive members 30A (30B) are performedsuccessively. This avoids complicated operation that electricalconnection is performed with extracting and moving at each time the tippart 51 of the electrical connection jig 50 from the gap 19. Thus, thecycle time in electrical connection is shortened, and hence productivityis improved.

Further, the plurality of electrical component assemblies 20 arearranged in two rows in the housing 10 in such a manner that a pair ofthe electrically conductive members 30A (30B) face each other betweenthe rows. Thus, the locations of welding between the electricallyconductive members 30A (30B) and the housing-side connection terminals16 are collected to a location between the electrical componentassemblies 20 which is a location between the rows. Thus, even in aconnection structure having a plurality of electrical componentassemblies 20, the cycle time can be reduced in the electricalconnection work. This improves productivity.

The intermediate wall 13 of the housing body 11 is provided with theopening 14 having an approximately quadrangular shape and capable ofaccommodating a plurality of electrical component assemblies 20.Further, the extension section 17 extending such as to bridge themutually opposing edges of the opening 14A is provided with the holdingsection 15A and the edge-side holding section 15B against which the endof the electrical component assembly 20 abuts so that positioning isachieved. Thus, in such a manner that the holding section 15A and theedge-side holding section 15B respectively abut against the one end andthe other end of the upper end wall 21 of the electrical componentassembly 20 so that positioning is achieved, the plurality of electricalcomponent assemblies 20 can be arranged into the opening 14 (thelongitudinal holes 14 a and 14 b).

Further, the large opening 14 is provided that is capable ofaccommodating a plurality of electrical component assemblies 20. Thus,the amount of resin material used in the intermediate wall 13 can bereduced as much as possible. Thus, weight reduction of the housing 10 isachieved.

Further, the extension section 17 bridges the mutually opposing edges 13a and 13 b of the opening 14. Thus, the electrical component assembly 20can abut compactly and effectively with desired strength.

Further, the holding section 15A and the edge-side holding section 15Bare provided with the notch 15 c with which the end piece 23 a of eachelectrical component assembly 20 is engaged. Thus, when the electricalcomponent assembly 20 is to be arranged into the opening 14, the endpiece 23 a of the electrical component assembly 20 is engaged with thenotch 15 c so that the electrical component assembly 20 can easily andreliably be positioned into the opening 14 (the longitudinal holes 14 aand 14 b). Thus, positioning of the electrical component assembly 20 isachieved easily, and so is the assembling work. This contributes toimprovement of productivity.

Further, the housing-side connection terminals 16 (the electricallyconductive members 16A) are insert-molded into the extension section 17.Thus, in a state that the electrical component assembly 20 ispositioned, the housing-side connection terminals 16 can be arrangednear the connection terminals 30 a and 30 b of the electrical componentassembly 20. Thus, space-saving is achieved, and electric connection iseasily performed between the housing-side connection terminals 16 andthe connection terminals 30 a and 30 b.

Further, in the extension section 17, the housing-side connectionterminals 16 are inserted in a middle part in the extension direction.Thus, the amount of use of resin material is reduced as much as possibleby the amount corresponding to the presence of the housing-sideconnection terminals 16. Thus, weight reduction of the housing 10 isachieved.

Further, the electrical component assembly 20 is accommodated in thehousing 10 in such a manner that the pair of electrically conductivemembers 30A and 30B are arranged in parallel with spacing in a directionequal to the vertical direction of the vehicle on which the apparatus ismounted. Thus, the electrical component assembly 20 has resistanceagainst vibrations in the vertical direction of the vehicle. That is,the pair of electrically conductive members 30A and 30B arranged up anddown with spacing receive forces tending to mutually cancel out (atensile force acting on one electrically conductive member 30A in theaxis direction is cancelled out by a compressive force acting on theother electrically conductive member 30B in the axis direction). Thisprovides resistance against vibrations in the up and down directionstransmitted from the vehicle side.

According to the brake control apparatus U employing the housing 10 ofthe present embodiment, size reduction is achieved in a state that acertain space used for insertion of the tip part 51 of the electricalconnection jig 50 is ensured in the housing 10.

Second Embodiment

A second embodiment of the present invention is described below. Adifference in the present embodiment from the first embodiment is thatthe extension section 17 is reinforced by reinforcement ribs 17 a and 17b.

As shown in FIGS. 11A and 11B, the reinforcement ribs 17 a and 17 bprotrudes in the axis direction of the electrical component assembly 20along the extension direction of the extension section 17, and has anapproximately triangular shape when viewed from the up and downdirections as shown in FIG. 11B.

As shown in FIG. 12A, in the reinforcement ribs 17 a and 17 b, thepedestal side is connected integrally to the wall 11 a surrounding theelectrical component assembly 20. Then, as shown in FIG. 12B, thereinforcement ribs 17 a and 17 b serve as a partition that partlyseparates from each other the electrical component assemblies 20 and 20adjacent in the up and down directions, in a part between the up and thedown longitudinal holes 14 a and 14 b.

According to the present embodiment, the reinforcement ribs 17 a and 17b are provided in the extension section 17. Thus, in spite of thestructure that the extension section 17 bridges over the opening 14, itsstrength is ensured so that the extension section 17 can appropriatelyposition and hold the electrical component assembly 20. Further, thereinforcement ribs 17 a and 17 b protrude in the axis direction of theelectrical component assembly 20 and hence can be arranged, for example,by using a space formed between adjacent electrical component assemblies20. This realizes space-saving.

The mode of implementing the present invention has been described above.However, the present invention is not limited to these embodiments, anddesign variations may be applied within a range not departing from thespirit of the present invention.

For example, the embodiments have been described for a configurationthat electrical connection between the electrically conductive members30A and 30B and the housing-side connection terminals 16 is performed inthe second accommodation chamber 11B. However, the configuration is notlimited to this. That is, these components may extend (protrude) intothe first accommodation chamber 11A, and then electrical connection maybe performed in the first accommodation chamber 11A. In this case, theelectrical connection jig 50 (electrode) may be moved into the firstaccommodation chamber 11A from the first accommodation chamber 11A side.Thus, such a configuration also provides an operation effect similar tothat described above.

Further, the number and the arrangement of electrical as componentassemblies 20 described in the embodiments are illustrative and do notplace any limit on the configuration.

Further, the embodiments have been described for a case that theelectrical component assembly 20 is composed of the coil device foropening and closing the solenoid valves 2 and 3 (see FIG. 1). However,the configuration is not limited to this. That is, the present inventionmay be applied to a connection structure for a fluid pressure detectionsensor (a pressure detecting sensor) and the other electrical componentsprovided in the base 1.

The assembled apparatus to which the electrical component assembly 20 isassembled is not limited to the brake control apparatus 0, and may beanother apparatus having electrical components.

What is claimed is:
 1. A method for producing a pair of electricallyconductive members assembled into an electrical component assemblyprovided with a coil, the method comprising: forming connection terminalsections provided in the pair of electrically conductive members byarranging the connection terminal sections facing each other from a sideto side direction and alternately opposite to each other with spacing inan up and down direction as arranged on each of the pair of electricallyconductive members, and by performing press punching of a metal plate;and after the press punching of the metal plate, bending the connectionterminal sections in the pair of electrically conductive members towarda side departing from the coil into a protruding form.
 2. The methodaccording to claim 1, further comprising: after the bending into theprotruding form, as a resin molding step, including by insert moldingthe bent portions of the connection terminal sections into a terminalsupporting section provided in a bobbin around which the coil is wound,wherein, by virtue of the resin molding step, the connection terminalsections are formed integrally with the bobbin.
 3. The method accordingto claim 1, wherein the press punching forms extension pieces from abase to be formed into the connection terminal sections.
 4. The methodaccording to claim 3, wherein the press punching of the connectionterminal sections further forms: tapered shape sections to be formedinto winding sections; first protruding pieces extending transversely totapered shape sections and to be formed into guide pieces; and secondprotruding pieces extending from the tapered shaped sections andtransversely from a base portion, which is to be formed into wireconnection sections.
 5. The method according to claim 4, wherein: theguide pieces and the second protruding pieces extend in the up and downdirection and in a transverse direction of a linkage section thatconnects the electrically conductive members; and the extension piecesextend in right and left directions in a longitudinal direction of thelinkage section and transversely to the first and second protrudingpieces.
 6. The method according to claim 5, wherein: a first extensionpiece of the extension pieces extends from a lower side of a center partof the base to be formed into an extending section, toward a secondextension piece side of the extension pieces; and the second extensionpiece extends from an upper side of the center part of the base towardthe first extension piece side.
 7. The method according to claim 6,wherein the first extension piece and the second extension piece arearranged opposite to each other with spacing in the up and downdirection and in such a manner that interference with each other isavoided.
 8. The method according to claim 7, wherein: the bending isperformed on the second protruding pieces of the electrically conductiveplates and on the extension pieces.
 9. The method according to claim 8,wherein: the second protruding pieces are bent from a middle part towardthe base such as to rise from a surface of the metal plate to a sidealong on a first bending line, and then bent toward a lower direction ofthe metal plate such as to face an upper face of the base.
 10. Themethod according to claim 9, wherein the extension pieces protrude atright angles relative to the surface of the metal plate, and the bendingis performed on the extension pieces along second bending lines toward aleft and a right such as to rise from the surface of the metal plate toa near side of the base.
 11. The method according to claim 10, whereinafter the bending, at a resin molding step, an insert molding isperformed such that bent portions of the extension pieces are formed asresin embedded sections.
 12. The method according to claim 11, furthercompromising integrally forming a bobbin with the bent portions of theextension pieces.
 13. The method according to claim 11, furthercomprising, after the insert molding, separating the electricallyconductive members from the linkage section.